( Reaffirmed 2000 ) Indian Shndard INTERNAL COMBUSTION ENGINESRADIATOR PRESSURE CAPSSPECIFICATION UDC 621'43 - 714 : 621'646'4 : 629'113 0 BIS 1990 BUREAU MANAK OF INDIAN 9 BAHADUR STANDARDS SHAH ZAFAR 110002 MARG BHAVAN, NEW DELHI December 1990 Price Croup 2 Automotive Primemovers Sectional Committee, TED 2 FOREWORD This Indian Standard was adopted by the Bureau of Indian Standards on 18 May 1990, after the draft finalized by the Automotive Primemovers Sectional Committee had been approved by the Transport Engineering Division Council. In this standard two types of pressure caps, namely, A and B depending on the nominal opening pressure of automotive radiators are covered. It also covers the systems having provisions for auxiliary tanks. IS 12996: 1990 Indian Standard INTERNAL COMBUSTION ENGINESRADIATOR PRESSURE CAPSSPECIFICATION 1 SCOPE 1.1 This standard specifies the general requirements and test methods for pressure caps used on radiator, particularly for automotive vehicles. 4.2 Auxiliary Tank A separate tank in the cooling system is provided to perform one OF more of the following functions: a) b) c) d) Filling, Coolant reservoir, Deaeration, Retention of coolant expelled by expansion and/or after boil, and e) Visible fluid level indication. 2 REFERENCES 2.1 The following Indian standards are necessary adjuncts to this standard: IS No. Title Cold rolled brass sheet, strip and foils ( third revision > tables: inspection Sampling 2500 (Part 1 ) : 1973 Part 1 Inspection by attributes and by count of defects (first 410 : 1977 revision ) 4.3 Deaeration The removal or purging of gases ( air, steam and/ or combustion gas > which have been entrapped in the coolant. 4.4 After Boil Boiling of the coolant following engine shutdown or slow idling after heavy loading caused by excessive residual heat in the engine. 4.5 Main Valve A device to release coolant/air/steam pressure rating of cap. 4.6 Vent Valve A device to release vacuum inside radiator/ cooling systems by allowing air/coolant from atmosphere or auxiliary tank at pre-rated pressure of cap to equalize the cooling system to atmospheric conditions. 5 GENERAL REQUIREMENTS 5.1 Dimensions and Tolerances These shall be as per agreement manufacturer and the purchasers. 6 MATERIAL 6.1 All metallic components of caps in contact with the coolant/steam shall be of brass conforming to IS 410 : 1977 or IS 3331 : 1977. The springs shall be of phosphor bronze conforming to IS 7608 : 1987. Alternatively, the sheets and spring wire shall be of stainless steel conforming to IS 5522 : 1978 and IS 4454 ( Part 4 ) : 1974 respectively. The rubber components shall be nitryl based and capable of withstanding temperatures up to 120°C. between the at pre-set 3331 : 1977 revision ) strips/ brass Copper and foils for radiator cores (J;rst Steel wires and cold formed 4454 (Part 4) : 1974 springs: Part 4 Stainless spring steel wire for normal corrosion resistance (first revision ) Stainless steel sheets and coils 5522 : 1978 Phosphor bronze wires for 7608 : 1987 engineering purposes general (first revision ) 7611 : 1975 3 TYPES 3.1 Depenging. Automotive radiators brass core construction copper the nominal opening upon pressure OI mam valve, the caps are categorized as given below: Type A B Pressure 50 kPa ( 0'5 kgf/cm2 ) 90 kPa ( 0'9 kgf/cm2 ) 3.2 The caps shall be of single or double acting depending on use for main and auxiliary tanks. 4 TERMINOLOGY For the purpose of this standard, the following definitions shall apply. 4.1 Radiator Cap A removable device which closes the cooling system filler neck and which incorporates both relief pressure and vacuum braking valves. IS 12996 : 1990 7 WORKMANSH[P AND FINISH 8.3 The following a) Initial b) Gasket seal. tests shall be carried pressure, and out: 7.1 The seal gasket shall be smooth and free The metallic parts shall be from cracks or tears. free from stains, oxidations or other similar defects. The caps shall be free from burrs. 8 PERFORMANCE 8.1 Operational TESTS opening 8.4 Initial Opening Pressure 8.4.1 Main Valve ( All Types ) Characteristics Testing shall be carried out on caps after ageing in a mixture of equal parts of water and suitable coolant solution at a temperature of 110°C for 72 hours and on caps after ageing in air at 110°C for 49 hours. 8.2 Before testing, the caps shall be rinsed in water at a temperature of 27 f 5°C to ensure removal of dirt, foreign matters from rubber of main and vent valves. It is then seating installed on suitable fixture having filler neck requirements conforming to IS 7611 : 1975 to simulate operating conditions with the cap installed on the radiator filler neck ( see Fig. 1 ). Table 1 Pressure Characteristics (Clauses Cap Components Install pressure cap under test on the fixture shown in Fig. 2 after connecting a hose to port RI. Immerse the hose in water. Another hose leading from a suitable source of air shall be connected to port R2. The control valve ( CVI ) iS opened. Air is gradually passed into Chamber A by operating control valve ( CV2 ). For caps without spring on the vent valve delivery of air shall be preceded by a slight crease in pressure to ensure vent valve closing. the in- The opening pressure of the main valve revealed be continuous flow of air bubbles through water shall be within the limits specified in Table 1. After the first measurement repeat the test with the cap rotated through 180" in relation to the first position. of Main and Vent Valves Top Seal 8.4.1, 8.4.2 and 8.5.1 ) Pressnre Rating kgf/cm2 h_--____~ A Characteristics C------Type 1.ype I3 0.9&O 15 0'005 to 0'20 0'5 Main valve Vent valve ( with calibrated spring) Top seal Both mounting condiGons Opening Testing with seal towards outside 0.5-j_-0'1 0'005 to 0'20 0'5 1OP SEAL ARRANGEMENT FOR CAP OPENING PRESSURE TEST 2 IS 12996 : 1990 CONTROL VALVE CV 2 I/ L PORT-R_1 PRESSURE GAUGE T R2 FIG. 2 ARRANGEMENT FOR MAIN VALVE TEST OPENING PRESSURE 8.4.2 Vent Valve ( Double Acting Types > Alternatively, be provided. an embossed cautionary figure may Install pressure cap under test on the fixture described in 8.2 ( see Fig. 3 ). The port R2 shall now be connected to a hose leading to a vessel containing water. Keep CV2 open. Admit air into Chamber B through port RI by operating CVI. Opening pressure of inlet valve, as revealed by air bubbles emerging from water, shall be within the limits specified in 8.4.1 ( see Table 1 ). 8.5 Top Seal Test ( for the Caps for Auxiliary Tanks ) 10 SAMPLING 10.1 Lot All the radiator pressure caps of the same type and size manufactured from the same material under similar conditions of production shall be grouped together to constitute a lot. 10.2 For ascertaining the conformity of the lot, the procedure for sampling and inspection as given in IS 2500 ( Part 1 ) : 1973 shall be followed. The type of sampling plan, inspection level and acceptable quality level ( AQL ) to be followed for various characteristics shall be as given in 10.2.1 and 10.2.2. 10.2.1 For ascertaining the conformity for dimensional requirements and workmanship and finish, a single sampling plan with Inspection Level IV and AQL of 2'5 percent as given in Tables 1 and 2 of IS 2500 ( Part 1 ) : 1973 shall be followed. 10.2.2 For operational test, a single sampling plan with Inspection Level II and AQL of 1'5 percent as given in Tables 1 and 2 of IS 2500 ( Part I ) : 1973 shall be followed. 11 PACKING lnstall pressure cap under test on the fixture described in 8.2. Close CV2 and cannect port Rl to an air pressure point using a suitable hose; totally immersed the fixture into a vessel containing water and gradually admit air through port RI by operating CVI. Leakage into the atmosphere as revealed by air bubbles emerging through cap gasket, shall occur at a pressure value greater than or equal to that specified in 8.4.1 ( see Table 1 ). 9 MARKING 9.1 Each cap shall be indelibly marked with the indication of source of manufacture, nominal opening pressure and date of manufacture. 9.2 A suitably worded warning may also be provided on the cap as a safety feature, as for example, `Allow to cool before opening'. 11.1 It shall be such as to protect damage. from any IS 12996:1990 CONTROL VALVE CV2 PRESSURE GAUGE FIG. 3 ARRANGEMENT FOR VENT VALVE OPENINGPRESSURE TEST 4 Standard Mark of the Bureau of Indian The Standard Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well defined system of inspection, testing and quality control which is devised and supervised by BIS and operated by the producer. Standard marked products are also continuously checked by BIS for conformity to that standard as a further safeguard. Details of conditions under which a licence for the use of the Standard Mark may be granted to manufacturers or producers may be obtained from the Bureau of Indian Standards. The use of the Standard Mark is governed by the provisions Standards Act, 1986 and the Rules and Regulations made thereunder. Bureap of Indian Standards BIS is a statutory institution established under the Bureau uf Indian Stundards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods b and attending to connected matters in the country. 9 Copyright No part of these publications may be BIS has the copyright of all its publications. any form without the prior permission in writing of BIS. This does not preclude the course of implementing the standard, of necessary details, such as symbols and sizes, designations. 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